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Float charge 220 V


Float charge/boost charge THYROTRONIC 200 A
Battery test
Mains fault
Unit fault
High voltage
Low battery voltage
Battery circuit fault
Battery test negative
Earth fault plus
Earth fault minus
Option 1
Option 2

LED Test / Reset

Rectifiers
for stationary battery systems
Standard thyristor-controlled rectifiers
THYROTRONIC Line
BENNING World Class Power Solutions
2
THYROTRONIC rectifier range
for stationary back up power supply
General
The protection of electrical load against power failure is often
carried out by battery backed up DC power supplies, providing
electrical energy to important loads during mains supply, as
well as during mains failure.

Fig. 1: Thyrotronic

Battery backed up DC power supplies have, over several The Thyrotronic rectifier range (see picture 1) developed by
decades proved extremely reliable and very economical BENNING is especially qualified for use as battery backed up
power supplies. power supplies and feature very high reliability and a com-
prehensive monitoring concept.
The reliability of a battery backed up DC power supply is
defined by the quality of the battery used, as well as the Thyrotronic rectifiers are operating with a controlled output
reliable operation of the rectifier. characteristic (IU-characteristic line in accordance with
DIN 41773).

The output voltage is kept constant to the set value with a


permissible deviation of 0,5 % within a load range between
Range of applications 0 % and 100 % of the unit current.

Power plants Mains voltage fluctuations of 10 % and mains


substations frequency fluctuations of 5 % will be controlled
Railway equipment automatically.
Offshore projects
Oil and gas pipeline systems As an energy storage mainly closed or vented lead acid
hospitals batteries are used. Nickel-cadmium batteries are used in
extreme ambient conditions.
BENNING World Class Power Solutions
3
Type table THYROTRONIC
rectifier range for multi-purpose use
Nom. No. of No. of Output Mains Current Cabinet Weight
voltage cells cells Current Type voltage consump. type
[V] Pb NiCd [A] [V] [A] [kg]

24 12 20 20 E 230 G 24 / 20 BWrug-TDG 230 4,6 WGZ 755 30


24 12 20 40 E 230 G 24 / 40 BWrug-TDG 230 9,2 WGZ 755 40
24 12 20 60 E 230 G 24 / 60 BWrug-TDG 230 13,6 UC 1566 60
24 12 20 80 E 230 G 24 / 80 BWrug-TDG 230 17,8 UC 1566 75
24 12 20 100 D 400 G 24 / 100 BWrug-TDG 3 x 400 5,5 UC 1566 150
24 12 20 125 D 400 G 24 / 125 BWrug-TDG 3 x 400 6,8 UC 1566 200
24 12 20 160 D 400 G 24 / 160 BWrug-TDG 3 x 400 8,7 UC 1566 240
24 12 20 200 D 400 G 24 / 200 BWrug-TDG 3 x 400 10,8 UC 1566 290
24 12 20 300 D 400 G 24 / 300 BWrug-TDG 3 x 400 19,0 UC 1866 400
24 12 20 400 D 400 G 24 / 400 BWrug-TDG 3 x 400 24,3 PSJ 1596 510

48 24 40 10 E 230 G 48 / 10 BWrug-TDG 230 4,6 WGZ 755 30


48 24 40 20 E 230 G 48 / 20 BWrug-TDG 230 9,1 WGZ 755 40
48 24 40 30 E 230 G 48 / 30 BWrug-TDG 230 12,3 UC 1566 60
48 24 40 40 E 230 G 48 / 40 BWrug-TDG 230 16,3 UC 1566 75
48 24 40 50 D 400 G 48 / 50 BWrug-TDG 3 x 400 5,8 UC 1566 145
48 24 40 60 D 400 G 48 / 60 BWrug-TDG 3 x 400 6,7 UC 1566 190
48 24 40 80 D 400 G 48 / 80 BWrug-TDG 3 x 400 8,9 UC 1566 220
48 24 40 100 D 400 G 48 / 100 BWrug-TDG 3 x 400 10,8 UC 1566 270
48 24 40 125 D 400 G 48 / 125 BWrug-TDG 3 x 400 13,8 UC 1566 290
48 24 40 160 D 400 G 48 / 160 BWrug-TDG 3 x 400 17,6 UC 1566 340
48 24 40 200 D 400 G 48 / 200 BWrug-TDG 3 x 400 21,9 UC 1866 400
48 24 40 300 D 400 G 48 / 300 BWrug-TDG 3 x 400 32,0 UC 1866 500
48 24 40 400 D 400 G 48 / 400 BWrug-TDG 3 x 400 48,0 PSJ 1896 600

60 30 50 10 E 230 G 60 / 10 BWrug-TDG 230 5,1 WGZ 755 30


60 30 50 20 E 230 G 60 / 20 BWrug-TDG 230 10,3 WGZ 755 40
60 30 50 30 E 230 G 60 / 30 BWrug-TDG 230 17,5 UC 1566 60
60 30 50 40 E 230 G 60 / 40 BWrug-TDG 230 20,4 UC 1566 75
60 30 50 50 D 400 G 60 / 50 BWrug-TDG 3 x 400 6,8 UC 1566 150
60 30 50 60 D 400 G 60 / 60 BWrug-TDG 3 x 400 8,1 UC 1566 220
60 30 50 80 D 400 G 60 / 80 BWrug-TDG 3 x 400 10,8 UC 1566 250
60 30 50 100 D 400 G 60 / 100 BWrug-TDG 3 x 400 13,5 UC 1566 280
60 30 50 125 D 400 G 60 / 125 BWrug-TDG 3 x 400 17,1 UC 1566 300
60 30 50 160 D 400 G 60 / 160 BWrug-TDG 3 x 400 21,7 UC 1566 350
60 30 50 200 D 400 G 60 / 200 BWrug-TDG 3 x 400 26,5 UC 1866 420
60 30 50 300 D 400 G 60 / 300 BWrug-TDG 3 x 400 40,5 UC 1866 520
60 30 50 400 D 400 G 60 / 400 BWrug-TDG 3 x 400 53,0 PSJ 1896 620

108 54 90 5 E 230 G 108 / 5 BWrug-TDG 230 4,0 WGZ 755 30


108 54 90 10 E 230 G 108 / 10 BWrug-TDG 230 8,0 UC 1566 40
108 54 90 16 E 230 G 108 / 16 BWrug-TDG 230 13,2 UC 1566 60
108 54 90 25 D 400 G 108 / 25 BWrug-TDG 3 x 400 6,5 UC 1566 75
108 54 90 30 D 400 G 108 / 30 BWrug-TDG 3 x 400 7,5 UC 1566 95
108 54 90 40 D 400 G 108 / 40 BWrug-TDG 3 x 400 10,0 UC 1566 180
108 54 90 50 D 400 G 108 / 50 BWrug-TDG 3 x 400 12,9 UC 1566 220
108 54 90 60 D 400 G 108 / 60 BWrug-TDG 3 x 400 14,7 UC 1566 260
108 54 90 80 D 400 G 108 / 80 BWrug-TDG 3 x 400 20,0 UC 1566 330
108 54 90 90 D 400 G 108 / 100 BWrug-TDG 3 x 400 24,7 UC 1566 400
108 54 90 125 D 400 G 108 / 125 BWrug-TDG 3 x 400 31,5 UC 1566 450
108 54 90 160 D 400 G 108 / 160 BWrug-TDG 3 x 400 40,0 UC 1866 500
108 54 90 200 D 400 G 108 / 200 BWrug-TDG 3 x 400 50,0 PSJ 1896 520
108 54 90 300 D 400 G 108 / 300 BWrug-TDG 3 x 400 70,0 PSJ 1896 850
108 54 90 400 D 400 G 108 / 400 BWrug-TDG 3 x 400 100,0 PSJ 2288 1100

216 108 180 5 E 230 G 216 / 5 BWrug-TDG 230 9,4 WGZ 755 40
216 108 180 10 D 400 G 216 / 10 BWrug-TDG 3 x 400 5,1 UC 1566 60
216 108 180 16 D 400 G 216 / 16 BWrug-TDG 3 x 400 8,0 UC 1566 80
216 108 180 20 D 400 G 216 / 20 BWrug-TDG 3 x 400 9,8 UC 1566 120
216 108 180 25 D 400 G 216 / 25 BWrug-TDG 3 x 400 12,4 UC 1566 220
216 108 180 30 D 400 G 216 / 30 BWrug-TDG 3 x 400 15,2 UC 1566 260
216 108 180 40 D 400 G 216 / 40 BWrug-TDG 3 x 400 21,0 UC 1566 330
216 108 180 50 D 400 G 216 / 50 BWrug-TDG 3 x 400 25,2 UC 1566 400
216 108 180 60 D 400 G 216 / 60 BWrug-TDG 3 x 400 30,5 UC 1566 450
216 108 180 80 D 400 G 216 / 80 BWrug-TDG 3 x 400 40,0 UC 1566 500
216 108 180 100 D 400 G 216 / 100 BWrug-TDG 3 x 400 50,0 UC 1566 620
216 108 180 125 D 400 G 216 / 125 BWrug-TDG 3 x 400 63,0 PSJ 1896 720
216 108 180 160 D 400 G 216 / 160 BWrug-TDG 3 x 400 81,0 PSJ 1896 800
216 108 180 200 D 400 G 216 / 200 BWrug-TDG 3 x 400 100,0 PSJ 2288 1050
216 108 180 300 D 400 G 216 / 300 BWrug-TDG 3 x 400 152,0 PSJ 221208 1300
216 108 180 400 D 400 G 216 / 400 BWrug-TDG 3 x 400 203,0 PSJ 221208 1600

Subject to technical change without notice, other types on request.


BENNING World Class Power Solutions
4
THYROTRONIC
rectifier range for multi-purpose use
Operation
Lead-acid and nickel-cadmium batteries achieve optimum Switching the charge characteristic, from float charging
service life when remaining on float, in a charged condition. (e.g. 2.23 V/cell with lead-acid batteries) to boost charging
The charger floats the battery in a charged state and also (2.4 V/cell with lead-acid batteries) gives an accelerated
supplies the load with power. In the event of mains power recharge which can be manual, dependent on voltage or
failure the battery will then supply the load its required dependent on voltage and time.
power. This is called "parallel operation" (see fig. 2).
With substantially discharged batteries, the rectifier unit at After the battery has been fully charged, a small charge
first operates in the I-branch of the IU-characteristic line, current flows (approx. 0.3 mA to 1 mA per 1 Ah) to balance
whereby the charging current for the batteries results from the internal losses of the battery.
the difference between the nominal current of the rectifier
unit and the load current. The required autonomy is taken into consideration for calcu-
When the set output voltage of the rectifier unit (U-branch) lating the battery size. The standby times vary depending on
has been reached, the unit is changed to constant voltage type of load and mains conditions.
charging (see fig. 3).

AC mains 230 / 3 x 400 V

power supply unit

battery

secured DC net

load

Fig. 2: Standby parallel operation

Typical values: Depending on type of load and


Volt / Cell mains conditions

charge 10 30 minutes
2.4 - for EDP-systems
2.3 float charge
2.23 1 3 hours
2.2 - energy supply
2.1 - process control
2.0 - rail way
[%] - air ports
0
- hospitals
0 20% 40% 60% 80% 100%
output current
2 10 hours
- telecommunication systems
- oil and gas industry
Fig 3: Charging characteristic for lead-acid batteries in
accordance with DIN 41773
BENNING World Class Power Solutions
5
THYROTRONIC
safe, reliable, powerful
Rectifier series Thyrotronic
The Thyrotronic series consists mainly of a thyristor-con-
trolled power unit and a microprocessor-controlled monitor-
ing and control unit.

The following main components are included:

mains input with contactor

mains transformer with separate windings

fully controlled 6 pulse three phase bridge with


semi conductor protection fuse (working primarily
as battery inverse polarity protection)

smoothing chokes and capacitor bank to reduce


ripple

control unit with digital setpoint setting

digital monitoring

display and operation unit with graphical LCD


display on the front door (see picture 5)

NH fuse loaded battery circuit breakers

2 pol NH load circuit breaker to be populated


with fuses or links for load circuit

Fig. 4: Thyrotronic interior view

Display and operation unit (see picture 5)


The display and operation unit mounted on the front door of The 4 LEDs integrated in the display above the push buttons
the Thyrotronic features a graphical LCD display to indicate are linked to fixed functions.
the status and the measurements in plain text, as well as Two spare LEDs can be linked to any external monitoring
17 LEDs controlled by the monitoring and control unit. units.

Float charge 220 V


Float charge/boost charge THYROTRONIC 200 A
Battery test
Mains fault
Unit fault
High voltage
Low battery voltage
Battery circuit fault
Battery test negative
Earth fault plus
Earth fault minus urgent failure (red)
Option 1
general failure (red)
Option 2
battery operation (yellow)
operation (green)
LED Test / Reset
BENNING World Class Power Solutions
6
THYROTRONIC
comprehensive alarm and monitoring concept
Functions of the signalling and monitoring unit:
In the rectifiers of the Thyrotronic range a very large moni- If, during the availability test, the values fall below the adjust-
toring concept with the following functions is included as ed limits, the message "battery test negative" will be indicat-
standard: ed by the corresponding LED and the common fault signalling
relay.
Mains monitoring After the test the rectifier automatically switches back to
In case of a mains failure, an electronic regulator block is boost charge or floating charge.
initiated and the LED and the "mains failure relay" will be
activated. If the mains voltage returns the unit is automatical- Earth fault monitoring
ly switched on after a set time. The earth fault monitoring function monitors the insulation
resistance of the DC-output to earth. Plus and minus are
Charger output monitoring measured and monitored alternately. If the insulation resist-
The charger output monitoring is a current-dependent low ance falls below the adjusted value (adjustable from 100 kOhm
voltage monitoring and monitors the IU-characteristic of the to 1 MOhm), this will be indicated by the LEDs and the
rectifier unit. common alarm.
If the charger output falls below a set value of 2,1 V/cell and
the output current falls below 90 % of the rated current the I*R Compensation
alarm will activate and indicate "unit fault". The correspon- With I*R Compensation it is possible to compensate for the
ding LED and the common relay will be activated. voltage drop on the cable between rectifier and battery by
entry of cable length and cross-section of the cable.
High voltage monitoring
If the output voltage rises too high (value is adjustable) due to Programmable float/boost charge change over
an internal or external interference, over 20 msec, the impulse If the battery voltage lowers due to mains failure or any other
blocking will be activated and the output voltage will be set circumstances the rectifier unit will work in current limit. If it
to zero. operates for more than 30 seconds after the charge start it
will automatically be switched over to boost charge charac-
This high voltage monitoring works as dynamic monitoring teristic. After the boost charge voltage (current limitation) has
with an automatic reset. If the monitoring activates 4 times been reached and after decreasing to < 90 %, a time stage
within a period of 30 seconds, the mains contactor will be will be activated. Upon expiry of the set time (0 to 6 h) it will
disconnected, the LED "high voltage" and common relay will automatically be switched back to float charge.
be activated.
The automatic charging can be switched off so that only a
Low battery voltage manual switch-over via the plastic foil key board on the front
If the battery voltage falls below a set value, e.g. 1,8 V/cell panel is possible. Switching back to float charge can be done
(value adjustable) during discharge in a case of mains failure, manually as well. If this is not done, the controller will switch
the alarm "low battery voltage" will appear. LED and common back as in the case of automatic charging.
alarm will be activated.
The switch-over to boost charge can be blocked by an exter-
Battery circuit test nal contact or a fixed bridge on the controller.
The battery circuit of the power supply system is tested cycli-
cally every 24 hours. For this, the rectifier output voltage is Equalise charge stage
dropped down to 1.9 V/C for a period of 5 secs. and, as a It is possible to switch to an equalise charge stage via a
result, the battery is discharged. At the same time, the bat- switch on the front panel.
tery voltage is checked. If the battery voltage stays above Here the voltage limitation will be abolished and the nominal
1.9 V/C, the battery circuit has no fault. If it falls below the unit current will be reduced to 20 % (adjustable from 20-30).
limiting value, a "battery circuit fault" will be indicated and An equalise and commissioning charge follows with an
the LED as well as the common fault signalling relay will be I-characteristic up to the final charge voltage of the battery.
activated. - Caution! - It is not intended that this test should
replace battery circuit monitoring! After switching to equalise charge, a timer automatically
switches back to the float charge on expiry of the set time
Battery availability test (16 hours to 72 hours).
During the battery availability test the rectifier output voltage Using an external contact or a fixed bridge at the regulator,
will be dropped and the battery will be discharged as is the the equalise charge can be blocked and a switch over to the
case during the battery circuit test. The battery will be dis- I-characteristic can be prevented.
charged down to an adjustable minimum voltage limit during
an adjustable time. These limits depend on the proportional Load sharing in parallel operation
battery capacity withdrawn during the discharge and can be Due to an internal bus connection between several rectifiers
taken from the discharging curves of the connected battery. an active load sharing of 10 % is possible.
BENNING World Class Power Solutions
7
THYROTRONIC
technical data

Technical data

Mains input General data


Input voltage (VAC) 230 10 % 1-phase EMC EN 61000-6-2,
3x400 10 % 3-phase EN 61000-6-3
Input current (A) see type table Rel. humidity (%) < 95 non condensing
Frequency (Hz) 50 5 % Audible noise (dB A) < 65 measured at 1m dis-
Power factor ~0.83 at nominal mains tance and half rectifier height
voltage and float charging Installation height (m) max. 1000 above sea level
(m) max. 2000 above sea level
with decrease to 92 %
Rectifier output I nominal
Output voltage (VDC) 24, 48, 60, 110, 125, 220 Cooling natural convection
Output current (A) see type table Ambient temperature (C) 0 40 with 100 % I nominal
Output current (%) 50 100 0 50 with 88 % I nominal
adjustment range rectifier current limit Storage temperature (C) - 20 to +70
(%) 0 50 battery charging Cabinet protection IP 20 IEC60529
current limit Cabinet Steel frame floor standing
Current accuracy (%) 2 cabinet, front door with
Characteristic IU in acc. DIN41773 double bit lock
@ float and boost Paint finish RAL 7035
Boost voltage (V/C) 2,4 lead acid battery structured powder coating
1,55 NiCd battery Volt free alarms mains failure
Float voltage (V/C) 2,23 lead acid battery battery voltage low
1,40 NiCd battery common alarm
Equalize voltage (V/C) 2,7 lead acid battery
1,7 NiCd battery Options
with reduced current Interfaces MOD Bus
Output Voltage (%) 5 Profibus
adjustment range additional relaycontacts
Voltage accuracy (%) 0,5 Higher IP protection
Ripple (%) < 5 rms eff. without battery Countercells
option < 2 rms without battery Analogue measuring instruments
Efficiency (%) 85 94 % type dependent Additional monitoring components

Cabinet type table option IP21

Cabinet type Dimensions (mm)


H W D
WGZ 755 758 534 470
H

PSJ 1564 1500 600 400


UC/PSJ 1566 1500 600 600
UC/PSJ 1866 1800 600 600
PSJ 1896 1800 900 600
PSJ 2288 2200 800 800
W
PSJ 221208 2200 1200 800
H

WGZ - wall mounted cabinet


PSJ - floor standing cabinet
UC - floor standing cabinet

W D D

PSJ - floor standing cabinet WGZ - wall mounted


cabinet
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